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Sensor Technology

for the Automotive Market

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Tyco Electronics Ltd. is a leading global provider of engineered electronic components, network solutions and wireless systems, with customers in more than 150 countries. We design, manufacture and market products for customers in industries from automotive, appliances and aerospace and defense to telecommunications, computers and consumer electronics. With over 8,000 engineers and worldwide manufacturing, sales and customer service capabilities, Tyco Electronics' commitment is our customers' advantage.

G LO B A L AU TO M OT I V E D I V I S I O N

S E N S O R T E C H N O LO GY

Contactless measuring eliminates interference effects, wear and tear, and provides increased reliability. Tyco Electronics, one of the largest technology providers for the automobile industry, offers contactless sensors for a variety of applications. As sensor manufacturer and processing partner, Tyco Electronics also provides project planning support for new sensor applications, assistance in the selection of the appropriate sensor technology for the respective application, and assistance with defining the corresponding mechanical, electrical and magnetic interface. Tyco Electronics has a broad electromechanical portfolio that includes robust housing technologies, connector systems, and temperature stable designs based on foil and cable networks. This combination of technologies and experience ensures that reliable and cost effective sensor solutions are available for all application types.

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PLCD sensor element for contactless travel and angualr measurement

U-magnet concept for magnetically biased sensors

SEMI-CONDUCTOR

SEMI-CONDUCTOR SENSORS

MAGNETOINDUCTIVE

A P P L I C AT I O N

REQUIREMENTS

SENSORS HALL EFFECT

MR

EFFECT

PLCD

SENSORS

T R AV E L

MEASUREMENT

Operating range < 15 mm Operating range > 15 mm

ANGLE MEASUREMENT

Tangential, operating range < 90° Axial, operating range > 90°

SPEED MEASUREMENT

I N T E G R AT I O N

REQUIREMENTS

Small Space Large Operating range position tolerance Large control distances (through structure walls)

ROBUSTNESS

High-precision performance with Mechanical load e.g. Vibration High-precision performance with high ambient temperature

A U T O M O T I VAT E D I N E V E R Y D E TA I L

Our global automotive research centers are setting the technological landscape by developing new technologies, products and production processes. The increasingly fast growing number of functions in present and future cars require varieties of powerful and versatile connection systems. We compare existing standards with alternative possibilities in which costs, functionality, dependability and serial production are the basics of our procedures.

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TECHNOLOGY

Tyco Electronics has focused on contactless sensors solutions special for high performing and sophisticated measurement tasks. Wear influences as well as mechanical interactions between sensor and application parts are then avoided. Beside the actual measurement requirements, the application conditions determine the choice of the appropriate sensor technology. For contactless measurements preferably magnetic sensor technologies are used:

· Semi-conductor sensors with integrated Hall · Semi-conductor sensors with MR elements · Magneto-inductive PLCD sensors · Temperature sensor devices

Table (p.4) compares the characteristic application profile of these important sensor technologies. Semi-conductor solutions with Hall and MR effect show their advantages in their very compact and slim design. They are also preferred in the design of complex sensor clusters. The combination with different magnet configurations, typical integrated or moving magnets obtains precise measurement results.

A very efficient and robust sensor technology is the Tyco Electronics patented PLCD (Permanentmagnetic Linear Contactless Displacement Sensor) Technology. For the linear position measurements this principle has various advantages. The magnetic-inductive measuring principle distinguishes for its very large operation tolerance field. This enables the renunciation for specially guided or stored slider and records reliably its highly precise measuring performance without any loss, not being influenced by metal abrasions. The necessary driving magnet can herewith be fixed directly on the setting element, whereas even driving distances through non-ferromagnetic walls with several millimetre thickness, are not an exclusion criteria for this measuring principle. A fully enclosed design guarantees the robustness of this measuring principle. Therefore the encapsulated sensor is completely sealed and temperature resistant up to 160 °C.

PLCD Gear & Shift travel sensor for Automated Manual Transmission

Door Locking Unit with integrated Hall-Devices

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COMPETENCIES

Tyco Electronics, as sensor manufacturer and development partner, utilizes its experience to provide customer support on project work of new sensor applications. Once the application has been analyzed, the suitable sensor technology is selected and the corresponding mechanical, electrical and magnetic interfaces are defined. The design of the magnetic interface in particular requires a close cooperation with the customer. Special attention is paid to the external influencing factors of the applications.

During the design of the magnetic circuits, analytical and empirical methods are used which take into account the magnetic polarization angle-error and the surrounding magnet field influences. State-of-the-art procedures, involving FEM calculations, are used to analyse or design magnetic circuits. Based on the results of these calculations, the properties of the magnet arrangement will be verified and optimised through prototype testing.

FEM calculation for dimensioning the magnetic sensor interface

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Specific integrated electronic units ensure reliable signal conditioning and implementation of additional functions such as advanced signal evaluations, generation of control signals and complex diagnostic features. The electronic functions are designed with efficient ASIC technologies.

The selection of materials is determined by technical constructive requirements as well as on the environmental conditions. The wide temperature-load profile, high vibration strains and many different chemical liquids define the requirements regarding robustness and sealing of the respective sensor technology. The product architecture is defined by the application space requirements and the required connector or pigtail requirements. For hermetic and oil-tight sealing the sensor housings are molded without blowholes and closed with laser-welded housing covers.

Extensive component tests and life tests under application conditions provide the proof for a reliable and durable sensor design.

PLCD sensor module for gear and shift measurement

Digital and linear position measurement for clutch master cylinder

P R O J E C T P L A N N I N G A N D A S S I S TA N C E

As sensor manufacturer and processing partner, Tyco Electronics also provides project planning support for new sensor applications, assistance in the selection of the appropriate sensor technology for the respective application, and assistance with defining the corresponding mechanical, electrical and magnetic interface.

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A P P L I C AT I O N S

Tyco Electronics offers a comprehensive portfolio of sensors for the automotive industry, including switching, travel, rotational, speed and temperature. The primary focus is on contactless technologies to ensure a high level measuring performance, longterm reliability, and the elimination of interference effects and wear and tear.

Tyco Electronics is the leading supplier for contactless sensors for hydraulic, pneumatic and electro-mechanical actuators used on cars, trucks and busses. Typical applications are: · Automated Transmission and Clutch Systems · Turbocharger, Throttle, Exhaust Gas Recirculation (EGR), Manifold Intake · Generator, Alternator · Electrical Powered Assisted Steering (EPAS) · Convertibles In addition to the controlled actuator segment, Tyco Electronics also offers a wide range of innovative and cost-effective sensor solutions for following applications: · Seat Sensors (track position, occupant weight, buckle) · Clutch- and Brake Pedal Switches · ABS Wheel Speed · Cam- and Crankshaft · Transmission Gear Wheels · Chassis Level · Door- and Tailgate Latches · Outer Air Temperature · Fuel Level

R E L AT E D

T E C H N O L O G I E S

INDUCTIVE SYSTEMS

MECHATRONICS

TERMINALS

&

CONNECTORS

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PLCD travel sensor for hydraulic cylinder

Integrated PLCD travel sensor for pneumatic cylinder

Contactless throttle position sensor

Seat track position sensor (integrated magnet)

Contactless and redundant brakelight switch (integrated magnet)

ALTERNATIVE POWER SYSTEMS

CABLE ASSEMBLY SYSTEMS

HIGH SPEED DATA NETWORKING

POWER DISTRIBUTION SYSTEMS

RELAYS

&

WIRELESS TECHNOLOGIES

SWITCHING MODULES

O T H E R

T Y C O

E L E C T R O N I C S

A U T O M O T I V E

T E C H N O L O G I E S

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T YCO E L E C T R O N I C S

"AT YO U R S E R V I C E "

@

Internet Homepage

www.tycoelectronics.com www.tycoelectronics.com/automotive

Tyco Electronics Online

The Tyco Electronics website is an innovative and interactive source for application information, product updates and technical solutions. Our step-by-step software makes our website intuitive and user-friendly to better serve you ! Please contact us at : www.tycoelectronics.com/automotive

Electronic Internet Catalog

www.catalog.tycoelectronics.com

Product Information Center (PIC)

You can rely on Tyco Electronics PIC Team to provide you support for answers to your general information or technical questions in an efficient and effective manner. To reach our PIC staff, please contact your local Tyco Electronics organization.

Product and Machine Literature

Tyco Electronics offers a variety of product specific catalogs, brochures and high impact flyers to help better serve you ! For more information on literature for Tyco Electronics' Global Automotive Division, please contact your local Tyco Electronics Organization or go to www.tycoelectronics.com/automotive

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T YCO E L E C T R O N I C S

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www.tycoelectronics.com 11

Tyco Electronics AMP GmbH AMPèrestr. 12-14 64625 Bensheim / Germany Phone: +49-(0)6251-133-0 Fax: +49-(0)6251-133-1600 www.tycoelectronics.com TE Logo and Tyco Electronics are trademarks Tyco Electronics AMP GmbH certified acc. ISO 14001 and ISO/TS 16949:2002 © 2007 Tyco Electronics Ltd. 1308086-2 Rev. 12-2007 3.5M ST

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